How to Build Sign Letters

3-D lettering stands out!

Well-designed, attractive exterior signage can make all the difference between a business that's noticed and grows or one that's overlooked and withers. Your business sign is your first opportunity to spark curiosity and create interest in your products or services. And while traditional, flat signs are frequently attractive, making a three-dimensional sign with letters that truly "stand out" will set apart any business that's eager to present itself as a cut above the competition.

Things You'll Need

• Computer and printer
• Internet access
• Letter material, such as wood or plastic
• Jigsaw
• Sandpaper or a sanding tool
• Waterproof paint or stain

Instructions

1. Search for "free fonts" in a search engine to identify some great sources for a type style for your sign. There are hundreds of free designer fonts available online, and there's sure to be several that can give your sign letters just the right look and feel for your business's brand and image. Once you find a great look for your lettering, download the font and save it to your computer's hard drive.

2. Install your new font with the font manager found in the Windows Control Panel. Click on the Windows "Start" button, then click on "Control Panel" to open the panel. Find the icon marked "Fonts" and double-click on it to open the fonts folder. Next, click on "File" in the upper, left hand corner in the command line, and click on "Install New Font. . .". In the dialog box that pops up, point the installer to the download font file you saved in step 1 and click on "Install."

3. Open Wordpad from the Windows Start Menu (found in the Accessories folder), then click on the little triangle on the right-hand end of the font box (directly under the program icons near the top of the screen on the left). The menu that appears will list all of the fonts you currently have installed on your computer. Navigate down the menu until you find the font you'd like to use and click on it.

4. Click on the size box next to the font box, and enter the number 240. You can now type a letter on the keyboard to display your letter in the font that you're using for your sign. Note the size of your letter along the ruler above the letter, or click on "File" followed by "Print Preview. . ." to see how it appears on an standard sheet of paper. Adjust the number in the size box until the letter appears at the size you want, then Select "File" and "Print" to print it on your printer.

5. Cut the letter out of the paper and lay it on top of the material you're using to make your letters out of (most commonly wood). Trace the letter onto the wood to create a guide for cutting the letter out with your jigsaw.

6. Cut out the "final letter", paying careful attention to make smooth, even lines and curves. It's sometimes best to leave a small margin around certain parts of difficult lettering, so that the final letter can be more finely shaped with a sanding tool or sand paper.

7. Sand the letter into it's final form, being sure to correct any jagged or crooked edges, until the letter has a clean, professional-looking shape.

8. Attach the letter to your sign and paint or varnish it with a waterproof or oil-based product. This coat must also protect the letter from weather damage, so be sure to leave no exposed portions of the letter.

Tips & Warnings

• A solid hardwood such as pine, maple or oak will work much better than using plywood or particle board. The latter are especially susceptible to moisture damage, so these materials are not recommended.

• Generally, bold, thick letters works best for exterior signage. . .especially signs that will be seen only for a moment while a driver glances at it. Avoid light or overly-ornate letter choices, as these are both hard to read at any distance, and are more difficult to make.

• Remember that exterior signs are subject to weather conditions at all times. Be sure that your letters are well-protected from water damage and securely fastened to your sign to minimize future maintenance needs.